Conductive reel

ABSTRACT

A reel ( 100 ) comprises: an adapter ( 101 ) having a shaft hole ( 104 ); a cylindrical-shaped core portion ( 102 ) where the adapter ( 101 ) is held on an inner periphery side thereof; and two disc-shaped flange portions ( 103 ) each being formed radially with respect to an axis of the core portion ( 102 ) so as to extend from an edge of the core portion ( 102 ), and a material for the adapter ( 101 ), which is different from materials for the core portion ( 102 ) and the flange portions ( 103 ), has an abrasion loss of not greater than 15 mg by 1000-cycle Taber abrasion test (load: 1 kgf, abrasion ring: CS-17). This realizes a conductive reel which can suppress dust generation from a part thereof where the dust generation is more likely to occur.

TECHNICAL FIELD

The present invention relates to a conductive reel which suppresses dust generation from a portion thereof where the dust generation is more likely to occur when the portion rubs against a shaft.

BACKGROUND ART

Conventionally, a long semiconductor-mounting circuit tape such as a TAB (Tape Automated Bonding) tape or a COF (Chip on Film) tape, which is a film-mounting semiconductor device, is often wound on a reel. For example, in a manufacturing process, in order to supply a target device with the semiconductor mounting circuit tape, the reel with the semiconductor-mounting circuit tape wound thereon is attached to a shaft, and the shaft is then rotated so that the tape is sequentially unreeled. Further, in shipping and transporting processes, the semiconductor-mounting circuit tape being wound on the reel is packed and transported.

After the semiconductor-mounting circuit tape is used by a user, an empty reel is collected. The reel collected after subjected to use is washed in a cleaning process before reused. In the cleaning process, the reel is soaked in a cleaning solution, and subjected to ultrasonic cleaning, and then dried by an air blower.

A conventional reel had a core portion with a shaft hole into which the shaft was fitted, wherein the core portion had such a shape that it is sealed off with a cavity formed inside. This gave rise to the following problem. That is, in the cleaning process, the solution stayed in the core portion, and the reel was therefore poorly dried.

To solve the problem, for example, Patent Literature 1 discloses a tape reel having a skeletal core portion. FIG. 14 shows a schematic shape of a tape reel 500 disclosed in Patent Literature 1. As shown in FIG. 14, a core portion 501 of the tape reel 500 has a skeletal shape in which finger hook portions 502 for holding the tape reel 500 with fingers inserted therein are formed. The core portion 501 arranged as such contributes to rise in efficiency of cleaning and drying in the cleaning process and improvement in reusability.

Not only the tape reel 500 disclosed in Patent Literature 1 but also another conventional reel is made from plastic material such as polystyrene (PS) and acrylonitrile butadiene styrene (ABS) from the viewpoints of cost and workability in molding the reel. Further, since the reel is used with the semiconductor-mounting circuit tape wound thereon, the reel should not be charged for product protection. Hence, carbon is mixed in the plastic material. The use of the carbon suitably provides conductivity to the reel, and enhances workability in molding the reel and stability of the reel quality.

Patent Literature 1

Japanese Patent Application Publication, Tokukai, No. 2004-75385 A (Publication Date: Mar. 11, 2004)

SUMMARY OF INVENTION

However, the conventional reels had the following problem. That is, at the insertion and removal of a shaft, dust is generated from a portion of the reel contacted with the shaft when such a portion is rubbed against the shaft. The plastic material used for the conventional reels are more likely to generate shavings. Such generated foreign dust contains carbon whose resistance ranges approximately from 10³Ω to 10⁴Ω. Therefore, when the foreign dust is deposited onto a wiring of a wound semiconductor-mounting circuit tape, leakage occurs with greatly high possibility.

The present invention has been made in view of the problem, and an object of the present invention is to provide a conductive reel which can suppress dust generation from a portion thereof where the dust generation is more likely to occur.

A conductive reel of the present invention, to attain the object, comprises: a first attaching portion having a first shaft hole; a cylindrical-shaped core portion where the first attaching portion is held on an inner periphery side thereof; and two disc-shaped flange portions each being formed radially with respect to an axis of the core portion so as to extend from an edge of the core portion, wherein a material for the first attaching portion, which is different from materials for the core portion and the flange portions, has an abrasion loss of not greater than 15 mg by 1000-cycle Taber abrasion test (load: 1 kgf, abrasion ring: CS-17).

Conventionally, in inserting and removing the shaft into/from the shaft hole, the shaft rubbed against the axial part, thereby easily generating shavings. The shavings contained carbon. Therefore, the depositing of the shavings onto the wiring of a wound TAB tape caused leakage with greatly high possibility.

However, the reel of the present embodiment is such that the first attaching portion, which has the first shaft hole where the shaft is inserted and removed, is made from the material of which abrasion loss is not greater than 15 mg by 1000-cycle Taber abrasion test. The material has a property of being less prone to dust generation. Therefore, the shavings are less likely to occur at the insertion and removal of the shaft. This makes it possible to prevent dust generation from a portion thereof where the dust generation is more likely to occur when the portion rubs against the shaft.

It is preferable to arrange the conductive reel of the present invention such that the material for the first attaching portion is made from a polyacetal resin. The abrasion loss of the polyacetal resin by 1000-cycle Taber abrasion test is 13 mg. The polyacetal resin is also superior in moldability.

It is preferable to arrange the conductive reel of the present invention such that materials for the first attaching portion, the core portion, and the flange portions have each a polymeric material mixed therein, and surface resistance of each of the first attaching portion, the core portion, and the flange portions is set in the range from 10⁷Ω to 10¹⁰Ω. This prevents occurrence of leakage, even if the generated foreign dust is deposited onto the wiring of the TAB tape.

It is preferable to arrange the conductive reel of the present invention such that a diameter of the core portion ranges from 120 mm to 130 mm. Conventionally, in a case of winding the TAB tape on which a semiconductor chip was mounted having a larger width in a longitudinal direction of the TAB tape, the TAB tape was wound with great warpage that caused a resin crack at the edge of the semiconductor chip, if the diameter of the core portion was small. Therefore, an embossed tape for cushioning was excessively wound in advance. This, however, increased usage of the embossed tape, resulting in no superiority in cost.

On the other hand, according to the above arrangement, the TAB tape on which the semiconductor chip is mounted having a larger width in the longitudinal direction of the TAB tape can be wound with little warpage, thus preventing the occurrence of the resin crack at the edge of the semiconductor chip. Also, it is possible to reduce usage of the embossed tape, which realizes superiority in cost.

It is preferable to arrange the conductive reel of the present invention such that the core portion comprises: an outwardly cylindrical portion that is in a shape of a hollow cylinder and forms an outward shape of the outwardly cylindrical portion; a tubular attaching portion, provided on an inner periphery side of the outwardly cylindrical portion, holding the first attaching portion inserted thereinto so that the first shaft hole of the first attaching portion substantially matches an axis of the outwardly cylindrical portion; and a plurality of ribs connecting between the outwardly cylindrical portion and the tubular attaching portion. The core portion has a skeletal structure in which inner space is divided along an axial direction. This makes it possible to improve cleaning and drying properties in the cleaning process for reuse of the reel.

It is preferable that the conductive reel of the present invention further comprises a second attaching portion, provided so as to be inserted into and removed from the first shaft hole of the first attaching portion, having a second shaft hole whose diameter is smaller than that of the first shaft hole.

According to the above arrangement, it is possible to attach the reel to a shaft having a diameter smaller than that of the first shaft hole, by placement of the second attaching portion that matches the shaft shape into the first shaft hole of the first attaching portion. The use of the second attaching portion makes it possible to accommodate various shafts, which enables the reel to be used in accordance with an environment where a user uses the reel. Further, the second attaching portion is attachable and detachable. Therefore, it does not take much time to attach and detach the second attaching portion.

It is preferable to arrange the conductive reel of the present invention such that a material for the second attaching portion has a polymeric material mixed therein, and surface resistance of the second attaching portion is set in the range from 10⁷Ω to 10¹⁰Ω. This prevents the occurrence of leakage, even if the generated foreign dust is deposited onto the wiring of the TAB tape.

It is preferable to arrange the conductive reel of the present invention such that the first shaft hole of the first attaching portion has a plurality of key grooves formed therein. This allows the shaft to be inserted easily, in a case that a rib for positioning is provided on an outer periphery surface of the shaft. If the shaft hole has only one key groove, stress concentration at the rotation of the reel is likely to occur on the one key groove, thereby causing breakage of the reel. However, provision of the plurality of key grooves allows the stress of the reel rotation to be scattered without concentrating on a single groove, thereby preventing the breakage of the reel.

It is preferable to arrange the conductive reel of the present invention such that on an outer periphery surface of the core portion, at least one slit is formed so that a length of the slit extends along an axial direction of the core portion. With this arrangement, the TAB tape and the embossed tape are inserted in layers and fixed in the slit before started to be wound. This enables the TAB tape and the embossed tape to be easily wound around the core portion.

It is desirable to arrange the conductive reel of the present invention such that a width of the slit ranges from 2 mm to 6 mm, so that the TAB tape and the embossed tape can be inserted into the slit and fixed therein. The width corresponds to a total thickness of the TAB tape and the embossed tape.

It is preferable to arrange the conductive reel of the present invention such that each of the flange portions have a plurality of openings that are provided symmetrically to extend in the axial direction of the core portion, the flange portion has a strength of not lower than 2.7 N, and a total area of the plurality of openings accounts for 25% to 30% of an area of an outer surface of the flange portion which surface is perpendicular to the axial direction of the core portion.

Conventionally, the flange portion had wide open areas, which reduced the strength of the flange portion and therefore easily caused warpage. Unfortunately, the warpage caused misalignment in winding the TAB tape. On the other hand, according to the above arrangement, the openings are provided. This makes it possible to secure working areas (for example, an action of putting hands in the areas) in attaching and detaching the TAB tape to/from the core portion and to make the warpage even while ensuring the strength of the flange portion.

It is preferable to arrange the conductive reel of the present invention such that, in order to secure the sufficient working areas, if the outer surface of the flange portion has an area that ranges from 115551 mm² to 117515 mm², each of the openings has an area of not smaller than 8000 mm².

It is preferable to arrange the conductive reel of the present invention such that the first attaching portion, the core portion, and the flange portions are gray in color. This enables dirt not to be made noticeable, thereby preventing an excessive testing. This makes it possible to increase frequency of reuse of the reel as much as possible.

As described above, the conductive reel of the present invention comprises: the first attaching portion having the first shaft hole; the cylindrical-shaped core portion where the first attaching portion is held on an inner periphery side thereof; and the two disc-shaped flange portions each being formed radially with respect to the axis of the core portion so as to extend from the edge of the core portion, wherein the material for the first attaching portion, which is different from the materials for the core portion and the flange portions, has an abrasion loss of not greater than 15 mg by 1000-cycle Taber abrasion test (load: 1 kgf, abrasion ring: CS-17).

Therefore, the first attaching portion, which has the first shaft hole where the shaft is inserted and removed, is made from the material of which abrasion loss is not greater than 15 mg by 1000-cycle Taber abrasion test. This material has a property of being less prone to dust generation. Therefore, the shavings are less likely to occur at the insertion and removal of the shaft. This realizes the conductive reel which can suppress dust generation from a portion thereof where the dust generation is more likely to occur when the portion rubs against the shaft.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 is an elevation view showing an embodiment of a conductive reel of the present invention.

FIG. 2 is a side view showing an embodiment of the conductive reel.

FIG. 3 is an elevation view showing a structure of an adapter of the conductive reel.

FIG. 4 is an elevation view photographically showing a structure of a core portion of the conductive reel.

FIG. 5 is an explanatory schematic view showing winding of a TAB tape around a core portion of a reel.

FIG. 6 is an explanatory schematic view showing winding of another TAB tape around a core portion of a reel.

FIG. 7 is an elevation view showing another structure of a core portion of the conductive reel.

FIG. 8 is an elevation view showing another structure of a flange portion of the conductive reel.

FIG. 9 is an elevation view showing the conductive reel to which a shipping label is affixed.

FIG. 10 is a plane view photographically showing a structure of an inner core member of the conductive reel.

FIG. 11 shows a manufacturing process of the conductive reel of the present invention.

FIG. 12 is a table showing critical widths of a semiconductor chip, relative to a combination of (i) a diameter of a core portion of the conductive reel and (ii) a thickness of a tape to be wound.

FIG. 13 is a graph showing a relationship between the diameter of the core portion of the reel and the critical widths of the semiconductor chip.

FIG. 14 is a perspective view showing a structure of the conventional reel.

FIG. 15 is an elevation view showing the core portion shown in FIG. 4.

FIG. 16 is a side view showing the core portion show in FIG. 4.

FIG. 17 is an elevation view showing the inner core member shown in FIG. 10.

REFERENCE SIGNS LIST

-   -   100 reel (conductive reel)     -   101 adapter (first attaching portion)     -   102 core portion     -   103 flange portion     -   104 shaft hole (first shaft hole)     -   105 key groove     -   106 adapter attaching portion (tubular attaching portion)     -   107 and 109 rib     -   108 slit     -   110 to 112 window (opening)     -   120 inner core member (second attaching portion)     -   121 shaft hole (second shaft hole)     -   150 shipping label     -   200 and 210 TAB tape     -   201 and 211 semiconductor chip

DESCRIPTION OF EMBODIMENTS

The following describes an embodiment of the present invention with reference to drawings.

FIG. 1 is an elevation view showing an exemplary structure of a reel 100 of the present embodiment. FIG. 2 is a side view showing an exemplary structure of the reel 100 of the present embodiment.

The reel 100 of the present embodiment, which allows a TAB tape including a film-mounting semiconductor chip to be wound thereon, is a conductive reel having conductivity for protection of the wound TAB tape. As shown in FIGS. 1 and 2, the reel 100 comprises: an adapter 101 (first attaching portion) having a shaft hole 104 (first shaft hole) for inserting and removing a shaft; a core portion 102 where the adapter 101 is held on an inner periphery side thereof and TAB tape is wound around an outer periphery surface thereof; and two flange portions 103 each formed radially with respect to an axis of the core portion 102 so as to extend from an edge (rim) of the core portion 102.

FIG. 3 is a view showing an exemplary structure of the adapter 101.

The adapter 101 is made from a polyacetal (POM) resin. The polyacetal resin has a low friction coefficient (0.35 or lower), great abrasion resistance and moldability, and characteristics (property) of generating a low amount of dust. However, this is not the only possibility. Alternatively, the adapter 101 may be made from a material having abrasion loss of not greater than 15 mg by 1000-cycle Taber abrasion test (load: 1 kgf, ring: CS-17), as a material having characteristics (property) of being less prone to dust generation. The abrasion loss by the Taber abrasion test is 22 mg for ABS resin and 13 mg for the polyacetal resin.

Further, the adapter 101 has a polymeric material mixed therein, and surface resistance (conductivity) of the adapter 101 is adjusted (set) in the range from 10⁷Ω to 10¹⁰Ω, preferably from 10⁸Ω to 10⁹Ω for prevention of electrostatic buildup. This prevents leakage caused by the depositing of generated foreign dust on the TAB tape.

As shown in FIG. 3, the adapter 101 is at least provided with: the shaft hole 104 that conforms to a shaft diameter; and four key grooves 105 formed in the shaft hole 104. Other internal shape of the adapter 101 is not particularly limited as long as the shape provides excellent moldability. As the shaft, a 1-inch shaft is generally used. Accordingly, the shaft hole 104 is formed having such a diameter that matches the diameter of the shaft. Further, the shaft has one positioning rib formed on an outer periphery surface thereof.

The key grooves 105 are provided so that the rib of the shaft is inserted thereinto. The four key grooves 105 are formed at 90° intervals. However, this is not the only possibility. Alternatively, two or more key grooves may be provided. This allows the shaft to be inserted easily. If the shaft hole has only one key groove 105, stress concentration at the rotation of the reel is likely to occur on the one key groove, thereby causing breakage of the reel. However, provision of two or more grooves allows the stress of the reel rotation to be scattered without concentrating on a single groove, thereby preventing the breakage of the reel.

FIG. 4 shows a photographic image of an exemplary structure of a core portion 102. FIG. 15 is an elevation view of the core portion 102 shown in FIG. 4. FIG. 16 is a side view of the core portion 102 shown in FIG. 4.

The core portion 102 is made from a PS resin, ABS resin, or any other resin used generally. This secures workability in molding, and also suppresses increase in cost. Alternatively, the material for the core portion 102 may be made from polycarbonate (PC) resin, polybutylene terephthalate (PBT) resin, polypropylene (PP) resin, or the like resin.

Moreover, the core portion 102 has a polymeric material mixed therein, and surface resistance of the core portion 102 is adjusted in the range from 10⁷Ω to 10¹⁰Ω, preferably from 10⁸Ω to 10⁹Ω for prevention of electrostatic buildup. This prevents leakage caused by the depositing of generated foreign dust on the TAB tape.

For example, specifically, as the material for the core portion 102, TOYOLAC Parel manufactured by TORAY Industries, Inc. is used. The TOYOLAC Parel is an alloy made from an ABS resin and an antistatic polymer. The antistatic polymer is made from polyetheresteramide resin (nylon 6-polyethyleneglycol copolymer). The antistatic polymer is dispersed in streaks so as to form successive layers. This effectively creates a leak path for electric charges and provides conductivity to the core portion 102.

The core portion 102 is cylindrical in appearance, and the TAB tape is wound around an outer periphery surface of the core portion 102. The core portion 102 has a diameter in the range from 105 mm to 130 mm. The use of the core portion 102 having the smallest diameter in such a diameter range will cause damage to a semiconductor chip in winding the TAB tape around the core portion. Meanwhile, the use of the core portion 102 having the largest diameter in such diameter range reduces a winding amount of the TAB tape, but decreases the possibility of damaging the semiconductor chip in winding the TAB tape around the core portion. The use of the core portion 102 having a diameter of greater than 130 mm is not preferable because it reduces the winding amount of the TAB tape, thereby causing poor productivity.

Conventionally, the diameter of the core portion 102 was 105 mm. In this case, as shown in FIG. 5, a TAB tape 200 on which a semiconductor chip 201 is mounted having a narrower width in a longitudinal direction of the TAB tape 200 can be wound without any problem in quality even if the diameter of the core portion 102 is small (105 mm). However, as shown in FIG. 6, a TAB tape 210 on which a semiconductor chip 211 is mounted having a larger width in a longitudinal direction of the TAB tape 210 is wound, if the diameter of the core portion 102 is small (105 mm), with a great warpage that easily causes a resin crack at the edge of the semiconductor chip 211. Unfortunately, this will damage a product. In a case that the diameter of the core portion 102 is 105 mm, damage to the product does not occur when the width of the semiconductor chip in the longitudinal direction of the TAB tape is 12.1 mm, which is a critical value (It should be noted that this applies when a thickness of the semiconductor chip is 0.63 mm, and a height thereof, which is a total thickness including a thickness of an embossed portion, is 1.1 mm.). To solve the problem, conventionally, an embossed tape used as a cushion was excessively wound in advance. This, however, increased usage of the embossed tape, resulting in no superiority in cost.

On the other hand, particularly, the diameter of the core portion 102 ranges from 120 mm to 130 mm, which enables the critical value of the width of the semiconductor chip in the longitudinal direction of the TAB tape which width does not damage the product to range from 12.1 mm to 13.4 mm (It should be noted that the thickness of the semiconductor chip is 0.63 mm, and the height thereof, which is the total thickness including the thickness of the emboss portion, is 1.1 mm). This prevents the warpage of the TAB tape 210, on which the semiconductor chip 211 is mounted having a large width in the longitudinal direction of the TAB tape 210 as shown in FIG. 6, and suppresses the occurrence of the resin crack at the edge of the semiconductor chip 211. As a result, the tape can be wound without any problem. Further, this can decrease in usage of the embossed tape, thereby realizing superiority in cost. Besides, this can avoid curling of the TAB tape. Hence, the diameter of the core portion 102 may be determined in the range from 120 mm to 130 mm according to design variations.

As shown in FIG. 4, the core portion 102 has a skeletal structure (hollow structure) in which an adapter attaching portion 106 (tubular attaching portion) where the adapter 101 is fitted and attached (inserted and held) is provided on the inner periphery side of the core portion 102, and a plurality of ribs 107 are provided so as to hold the adapter attaching portion 106 and connect between a cylindrical portion (outwardly cylindrical portion) forming the outer periphery surface of the core portion 102 and the adapter attaching portion 106.

The adapter attaching portion 106 is formed in the shape of a tube that extends in the axial direction of the core portion 102, and is provided at such a position that an axis of the shaft hole 104 of the adapter 101 substantially agrees with the axis of the core portion 102 in attaching the adapter 101 to the adapter attaching portion 106. The ribs 107 have a structure with such strength that the ribs do not break when the reel 100 is rotated while the shaft is inserted into the adapter 101 attached to the adapter attaching portion

Thus, the skeletal structure of the core portion 102 allows reduction in usage of the resin. Further, the core portion 102 has such a shape and structure that liquid does not stay, which increase efficiency of cleaning with a solution, warm water and an air blower. This makes it possible to improve cleaning and drying properties in a cleaning process (process for removal of foreign materials) for reuse of the reel.

A shape of the ribs 107 is not limited to the shape (structure) shown in FIG. 4 as long as the ribs 107 have the above-specified strength. Alternatively, for example, ribs 109 as shown in FIG. 7 may be adopted. The ribs 109 are formed in the shape of a cross when seen along the axial direction of the core portion 102. Further, if the reduction of usage of the resin and improvement of the cleaning and drying properties are not needed, the ribs may have such a shape that the core portion 102 is sealed off as long as the ribs have the above-specified strength.

On the outer periphery surface of the core portion 102, four or more slits 108 are provided in such a manner that the length of each of the slits 108 extends along the axial direction of the core portion 102. The TAB tape and the embossed tape are inserted and fixed into the slits 108 before started to be wound. This enables the TAB tape and the embossed tape to be easily wound around the core portion 102. A width of the slits 108 ranges from 2.0 mm to 6.0 mm. The width is determined so that the TAB tape and the embossed tape are fixed in the slits 108 by a total thickness of the two tapes when inserted into the silts 108.

The flange portions 103 and the core portion 102 are molded into one piece. For this reason, the material for the flange portions 103 is the same as that for the core portion 102. Therefore, surface resistance of the flange portions 103 is also adjusted in the range from 10⁷Ω to 10¹⁰Ω, preferably from 10⁸Ω to 10⁹Ω for prevention of electrostatic buildup. This prevents leakage caused by the depositing of generated foreign dust on the TAB tape.

As shown in FIG. 1, each of the flange portions 103 is in the shape of a disc outwardly, wherein four windows 110 (openings) are provide. For example, the four windows 110 are provided symmetrically in four areas out of six separate areas of an outer surface of the flange portion 103 perpendicular to the axial direction of the core portion.

The windows 110 are openings which function as working areas (for example, an action of putting hands in the areas) in winding the TAB tape around the core portion 102. Therefore, it is desirable that the areas are wide from the viewpoint of material cost as well. Conventionally, the flange portion had wide open areas, which reduced the strength of the flange portion and therefore easily caused warpage. Unfortunately, the warpage caused misalignment in winding the TAB tape.

In view of this, the four windows 110 are provided symmetrically, the strength of the flange portion 103 is 2.7 N or more, and the total surface area of the four windows 110 accounts for 25% to 30% of an area of the outer surface of the flange portion 103 perpendicular to the axial direction, in order to secure the working areas, to maintain the strength of the flange portion 103, and to make the warpage of the flange portion 103 even. It is not preferable that the total surface area of the windows 110 is less than 25% of the area of the outer surface of the flange portion 103. This is because it increases the usage of the resin and therefore causes rise in cost.

Further, it is not preferable that the total surface area of the windows 110 is more than 30% of the area of the outer surface of the flange portion 103. This is because it cannot secure the strength of the flange portion 103.

Further, if the area of the outer surface of the flange portion 103 perpendicular to the axial direction ranges from 115551 mm² to 117515 mm², the area of each of the windows 110 is preferably not smaller than 8000 mm² so that the working areas are sufficiently secured. Furthermore, it is desirable that the flange portion 103 has areas (solid portion) where the windows 110 are not provided which areas are provided symmetrically, so that the warpage falls within 1.5 mm.

The shape and number of the windows 110 are not limited to those shown in FIG. 1. Alternatively, for example, the windows 111 and 112 of shapes as shown in FIG. 8 may be adopted. Further, as shown in FIG. 9, at the stage of shipment, a shipping label 150 (for example, 50 mm×100 mm) indicating information of a TAB tape is affixed to either of the flange portions 103. Therefore, it is desirable that each of the flange portions 103 has an area, as the solid portion, where the shipping label 150 can be affixed.

As described above, the reel 100 of the present embodiment comprises: the adapter 101 having the shaft hole 104 for inserting and removing a shaft; the core portion 102 where the adapter 101 is held on the inner periphery side thereof and the TAB tape is wound around the outer periphery surface thereof; and the two flange portions 103 each being formed radially with respect to the axis of the core portion 102 so as to extend from the edge of the core portion 102, wherein the adapter 101 is made from the polyacetal resin which is different from materials for the core portion 102 and the flange portions 103.

Conventionally, in inserting and removing the shaft into/from the shaft hole, the shaft rubbed against the axial part, thereby easily generating shavings. The shavings contain carbon whose resistance ranges approximately from 10³Ω to 10⁴Ω. Therefore, the depositing of the shavings onto the wiring of the wound TAB tape caused leakage with greatly high possibility.

However, the reel 100 of the present embodiment is such that the adapter 101 having the shaft hole 104 for inserting and removing the shaft is made from a polyacetal resin. The polyacetal resin has characteristics (property) of being less prone to duct generation. Therefore, the shavings are less likely to occur at the insertion and removal of the shaft. Accordingly, it is possible to realize the reel 100 which can suppress dust generation from a portion thereof where the dust generation is more likely to occur when the portion rubs against the shaft.

From the viewpoint of suppression of dust generation, it is considered that the core portion 102 and the flange portions 103 may also be made from a polyacetal resin. However, the polyacetal resin has a high shrinkage which ranges from 1.6% to 2.0% at the molding. Therefore, it is difficult to stably mold such a polyacetal resin into a large-size product, because deformation, asperity, and the like defects noticeably occur during the molding. On the other hand, the reel 100 of the present embodiment has no problem in moldability because the polyacetal resin is used only for the adapter 101 which is small in size. Accordingly, it is possible to stably mold the core portion 102 and the flange portions 103.

Further, the shaft attached to the reel 100 is generally a 1-inch shaft; however, there are various shaft shapes. Therefore, in order to accommodate a shaft shape varying depending on an environment where a user uses the reel, a dedicated inner core member can be used.

FIG. 10 shows a photographic image of an exemplary structure of an inner core member 120 being fitted into the shaft hole 104 of the adapter 101. FIG. 17 is an elevation view of the inner core member 120 shown in FIG. 10.

The inner core member 120 (second attaching portion) is used by fitting into the shaft hole 104 of the adapter 101. Therefore, the inner core member 120 can be inserted into and removed from the shaft hole 104 of the adapter 101. For example, an outer periphery surface of the inner core member 120 is tapered so that the inner core member 120 is fixed.

The inner core member 120 is made from a polyacetal resin. The inner core member 120 has a polymeric material mixed therein, and surface resistance of the inner core member 120 is adjusted in the range from 10⁷Ω to 10¹⁰Ω, preferably form 10⁸Ω to 10⁹Ω, for prevention of electrostatic buildup. This prevents leakage caused by the depositing of generated foreign dust on the tape.

As shown in FIG. 10, the inner core member 120 is at least provided with a shaft hole 121 (second attaching portion) that matches the shaft shape, and other internal shape of the inner core member 102 is not particularly limited as long as the shape of the inner surface provides excellent moldability. The shaft hole 121 is formed in such a shape so as to allow a φ8 mm-shaft with double wings, a φ8 mm-short shaft with a single wing, or the like shaft to be fitted into.

Thus, it is possible to attach the reel 100 to a shaft having a diameter smaller than that of the shaft hole 104 of the adapter 101, by placement of the inner core member 120 having the shaft hole 121 that matches the shaft shape into the shaft hole 104 of the adapter 101. The use of the inner core member 120 makes it possible to accommodate various shafts, which enables the reel to be used in accordance with an environment where the user uses the reel. Further, the inner core member 120 is attachable and detachable. Therefore, it does not take much time to attach and detach the inner core member 120, thereby realizing improvement in workability.

Further, according to the reel of the present embodiment, the following components: the adapter 101; the core portion 102; the flange portions 103; and the inner core member 120 are preferably gray in color. A natural color of a resin is generally white or milky-white. A direct use of such a resin without being colored enables cost reduction and ease of discovering dirt, thereby allowing the timing of replacement to be recognized easily and ensuring the quality of the reel.

However, in a case that the reel may be used in a process that goes under a greatly dirty environment, it would be impossible to reuse the reel. In order to increase frequency of reuse of the reel as much as possible, the reel is colored gray to prevent the dirt from being made noticeable, for the purpose of preventing an excessive testing. In order to color the resin gray, a pigment is mixed into a melted resin so as to increase a chromaticity at the molding stage.

The following describes a manufacturing process of the reel 100 of the present embodiment.

FIG. 11 shows the manufacturing process of the reel 100.

The manufacturing process of the reel 100 of the present embodiment comprises the steps of: (i) forming a reel body including the core portion 102 and the flange portions 103; (ii) forming the adapter 101 and the inner core member 120; and (iii) attaching the adapter 101 to the adapter attaching portion 106 of the core portion 102 after the steps (i) and (ii).

In the step of forming the reel body, resin chips are firstly prepared as materials for the core portion 102 and the flange portions 103 (S11). Then, the resin chips are put into a mold and melted to mold the core portion 102 and the flange portions 103 into one piece (S12). This forms the reel body including the core portion 102 and the flange portions 103. The molding may be double-port molding where the resin is supplied into the mold from two ports for molding. This makes it possible to improve productivity. The core portion 102 and the flange portions 103 are not necessarily molded into one piece, but may be molded separately and then bonded to each other.

In the step of forming the adapter 101 and the inner core member 120, the resin chips are firstly prepared as materials for the adapter 101 and the inner core member 120 (S21). Then, the resin chips are put into a mold and melted to mold the adapter 101 and the inner core member 120 (S22). This forms the adapter 101 and the inner core member 120. The adapter 101 and the inner core member 120 are molded separately. Further, the molding may be the double-port molding.

After the reel body and the adapter 101 are formed in the individual steps, the adapter 101 is attached to the adapter attaching portion 106 of the core portion 102. As a result, the reel 100 is completed. The adapter 101 is attached thereto removably. This enables replacement of the adapter 101 only. At the use of the reel 100, the shipment of the reel 100 to the user, or the like stage, the inner core member 120 may be attached to the adapter 101 as appropriate, or the inner core member 120 may be enclosed with the reel 100 for the shipment.

Example

With the reel 100 shown in FIG. 1, it was examined that to what degree a longitudinal width of a semiconductor chip on a TAB tape to be wound around the core portion 102 could be increased until the TAB tape became damaged, relative to a diameter of the core potion 102. In a case that the TAB tape is actually wound around the reel 100, an embossed tape for cushioning is wound together with the TAB tape for protection of the TAB tape. Therefore, the examination in the present example was conducted under conditions where the embossed tape was wound together with the TAB tape.

The TAB tape had a film of 38+8 μm (46 μm) in thickness and the semiconductor chip of 0.63 mm in thickness. The embossed tape had an embossed portion formed by an embossing process and a film of 0.125 mm in thickness. The used embossed tapes were such that respective heights thereof were 1.1 mm and 1.2 mm wherein the height was a total thickness including a thickness of the embossed portion. The used reels 100 were such that diameters of the core portion 102 ranged from 105 mm to 130 mm at intervals of 5 mm.

Under the above conditions, a critical width “w” of the semiconductor chip was calculated by the following equation:

w=2×√(N ² −M ²)

where N is a core radius+a height which is a total thickness including a thickness of the embossed portion (m m), and M is a core radius+a thickness of the film of the embossed tape+a thickness of the semiconductor chip (mm))

FIG. 12 shows the results. FIG. 13 is a graph based on the resulting data shown in FIG. 12. With reference to FIG. 13, a product is damaged in an area where dots exist. Further, productivity decreases in a shaded area where the diameter of the core portion 102 exceeds 130 mm.

The present invention is not limited to the description of the embodiments above, but may be altered by a skilled person within the scope of the claims. An embodiment based on a proper combination of technical means disclosed in different embodiments is encompassed in the technical scope of the present invention.

INDUSTRIAL APPLICABILITY

The present invention is not only suitably applied to a conductive reel which allows a TAB tape to be wound on and which is used by attachment to a shaft, but also broadly used in fields related to a manufacturing method of the conductive reel and manufacture of components used for the conductive reel. 

1. A conductive reel comprising: a first attaching portion having a first shaft hole; a cylindrical-shaped core portion where the first attaching portion is held on an inner periphery side thereof; and two disc-shaped flange portions each being formed radially with respect to an axis of the core portion so as to extend from an edge of the core portion, wherein a material for the first attaching portion, which is different from materials for the core portion and the flange portions, has an abrasion loss of not greater than 15 mg by 1000-cycle Taber abrasion test (load: 1 kgf, abrasion ring: CS-17).
 2. The conductive reel as set forth in claim 1, wherein: the material for the first attaching portion is made from a polyacetal resin.
 3. The conductive reel as set forth in claim 1, wherein: the materials for the first attaching portion, the core portion, and the flange portions have each a polymeric material mixed therein, and surface resistance of each of the first attaching portion, the core portion, and the flange portions is set in a range from 10⁷Ω to 10¹⁰Ω.
 4. The conductive reel as set forth in claim 1, wherein: a diameter of the core portion ranges from 120 mm to 130 mm.
 5. The conductive reel as set forth in claim 1, wherein: the core portion comprises: an outwardly cylindrical portion that is in a shape of a hollow cylinder and forms an outward shape of the outwardly cylindrical portion; a tubular attaching portion, provided on an inner periphery side of the outwardly cylindrical portion, holding the first attaching portion inserted thereinto so that the first shaft hole of the first attaching portion substantially matches an axis of the outwardly cylindrical portion; and a plurality of ribs connecting between the outwardly cylindrical portion and the tubular attaching portion.
 6. The conductive reel as set forth in claim 1, further comprising: a second attaching portion, provided so as to be inserted into and removed from the first shaft hole of the first attaching portion, having a second shaft hole whose diameter is smaller than that of the first shaft hole.
 7. The conductive reel as set forth in claim 6, wherein: a material for the second attaching portion has a polymeric material mixed therein, and surface resistance of the second attaching portion is set in the range from 10⁷Ω to 10¹⁰Ω.
 8. The conductive reel as set forth in claim 1, wherein: the first shaft hole of the first attaching portion has a plurality of key grooves formed therein.
 9. The conductive reel as set forth in claim 1, wherein: on an outer periphery surface of the core portion, at least one slit is formed so that a length of the slit extends along an axial direction of the core portion.
 10. The conductive reel as set forth in claim 9, wherein: a width of the slit ranges from 2 mm to 6 mm.
 11. The conductive reel as set forth in claim 1, wherein: each of the flange portions have a plurality of openings that are provided symmetrically to extend in the axial direction of the core portion, the flange portion has a strength of not lower than 2.7 N, and a total area of the plurality of openings accounts for 25% to 30% of an area of an outer surface of the flange portion which surface is perpendicular to the axial direction of the core portion.
 12. The conductive reel as set forth in claim 11, wherein: if the outer surface of the flange portion has an area that ranges from 115551 mm² to 117515 mm², each of the openings has an area of not smaller than 8000 mm².
 13. The conductive reel as set forth in claim 1, wherein: the first attaching portion, the core portion and the flange portions are gray in color. 